C.A. Ulven, Assistant ProfessorMechanical Engineering Department

North Dakota State University (NDSU)

Collaborators:V. Chevali, S. Pryor, I. Akatov, D. Wiesenborn , & C. Gustafson

– North Dakota State University (NDSU)S. McKay & M. Alcock – Composite Innovation Centre (CIC)

B. Tande & W. Seames – Univ. of North Dakota (UND)D. Kottke & D. Huotari – SpaceAge Synthetics, Inc. (SAS)

Current NDSU Students:M. Fuqua, S. Huo, L. Gibbon, J.D. Espinoza-Perez, W.

Manamperi, M. Hanson, & M. Azure

Biocomposites: Opportunities for ND Agricultural Byproducts

Motivation for Biocomposite Materials Research

Biocomposite materials will emerge as an important engineering material as the technology evolves through

strong collaboration by several facets of the entire production

Farmers & Processors

Composite Manufacturers

Commodity Groups

University & Industry

Researchers

Research Approach

A multidisciplinary team has been assembled focused on improving the growth, harvesting, treatments, and

development of new agri-based precursors for processing structural biocomposites in local and regional composite

manufacturing facilities for use in a wide range of applications.

Biocomposite Project Areas

Short Fiber ResearchUtilization of “waste” cellulose fiberDDGS, Sunflower, Sugar Beet, Canola, etc.

Long Fiber ResearchUtilization of residual flax, hemp, grasses, etc.Aspect Ratios (L/D) >2000

Biobased Resin Research Deriving polymer matrices from plant constituentsOils, Proteins, Starches, etc.

Byproducts Explored To-Date for Short Fiber Biocomposites

*Fibers:Flax, flax shive, hemp,

sugar beet pulp, sunflower hull, DDGS, corn chaff, corn cob,

canola meal, etc.

*Polymers:Polypropylene, polyethylene, polymethyl

methacrylate, vinyl ester, epoxy, etc.

*Fiber volume fractions from 5-50%*Multitude of chemical treatments

Short Fiber Biocomposite Results

Injection Molded Polypropylene (PP) w/ 10 wt% fiber loading

*Other fibers to be investigated shortly include: oat hull, pea hull, soybean hull, etc.

Short Fiber Biocomposite Results Cont.

Reinforcement Relative CTE (PP=1)

DDGS ‐ 10 w/w 0.92

DDGS ‐ 30 w/w 0.60

DDGS ‐ 50 w/w 0.35

SFH ‐ 10 w/w 0.71

SFH ‐ 30 w/w 0.49

SFH ‐ 50 w/w 0.28

Rice Hull Flour ‐ 10 w/w [8] 0.90

Rice Hull Flour ‐ 30 w/w [8] 0.75

Wood Flour ‐ 10 w/w [8] 0.79

Wood Flour ‐ 30 w/w [8] 0.52

Talc ‐ 25 w/w [2] 0.55

CaCO3 ‐ 40 w/w [4] 0.75

Silica ‐ 40 w/w [4] 0.75

Mica ‐ 40 w/w [4] 0.43

Carbon ‐ 15 w/w [5] 0.24

Coefficient of Linear Thermal Expansion – Polypropylene (PP)

*Other properties to be investigated shortly include: impact, heat distortion temp., UV resistance, moisture absorption, etc.

Other Polymers Being Investigated…

Polymethyl methacrylate (PMMA) reinforced with 10 wt% Sunflower Hull fiber increases both strength and stiffness

*Other polymers to investigated shortly include: acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), and post-

industrial recycled polyolefins (LDPE, HDPE, PP, etc.)

Short Fiber Biocomposite Product Processing Trials

Biocomposite materials from NDSU are being/have been evaluated by different molding facilities throughout the U.S.

– Great Plains Plastic Molding, Fargo, ND– Steinwall, Inc., Coon Rapids, MN– Advanced Tooling Concepts, Longmont, CO– Molded Materials, Inc., Plymouth, MI

*Trial structural step parts produced with NDSU biocomposite material by Great Plains Plastic Molding

Most Recent Short Fiber Biocomposite Developments…

“The partnering with Dr. Chad Ulven and his research group in the Mechanical Engineering Department at NDSU will help our company with

the numerous applications for new materials we have indentified.” according to Sam McCord, President & CEO of MCG BioComposites, LLC.

New partnership with MCG BioComposites, LLC based in Cedar Rapids, Iowa, to provide technical assistance in developing biocomposite materials for industrial and commercial applications…

Long Fiber Biocomposite Results

• Flax and hemp fibers have been investigated using a multitude of chemical surface treatments

• Results show tensile, flexure, & interfacial strength to increase but stiffness to decrease as a result of chemical treatment

• Results indicate flax and hemp can compete with fiberglass in composite applications

vs.

Long Fiber Biocomposite Technology Demonstrator

Randomly orientated flax fiber mat / polyester composite protective cover for a hydrogen tank mounted on the front end of an experimental hydrogen assisted diesel tractor at NDSU

Protection from impact, environmental

degradation, etc.provided for tank

Biobased Polymer Composites

• Epoxy thermoset resin from canola oil is the 1st objective

• Epoxy resins from other vegetable oils and blends with linseed, corn, soy, etc. will follow

• Proteins blended with synthetic thermoplastics is the 1st objective

• Improving toughness for damage tolerant materials is underway

Work with Faculty and Pilot Plant Facilities at Department of Agricultural and Biosystems

Engineering at NDSU

Development of International Biocomposite Working Group

*Partners from Canada, Australia, New Zealand, South Africa, and US: www.biocompositesinternational.org

Acknowledgements

Funding To-Date (3 yrs, over $350k):• AGCO Corporation• Composites Innovation Centre (CIC)• ND Corn Council• US DoE / ND EPSCoR – SUNRISE• NSF / ND EPSCoR – Startup & AURA Program• National Canola Growers Association• USDA / CSREES National Research Initiative Competitive Grants Program

Funding Next 3 yrs (over $500k):• ND Center of Excellence – SUNRISE BioProducts• Composites Innovation Centre (CIC)• AGCO Corporation• ND Corn Council• Steinwall, Inc.

Students:Graduate - M. Fuqua, S. Huo, M. Hanson, D. Huotari, S. Mekic, W.

Manamperi, J.D. Espinoza-Perez, M. Tatlari, A. Thapa, & L. Gibbon, Undergraduate – B. Aakre, E. Hall, E. Kerr-Anderson, B. Miller, A. Reich, N.

Sailer, L. Dionne, N. Miller, T. Hein, & Several ME Senior Design Teams